Road marker with solid body and lens protection

ABSTRACT

A road marker configured to withstand the force of a tire of a vehicle travelling over the road marker is provided. The road marker includes at least one lens, and a body having a trapezoidal cross section. The body includes a flat top, a bottom wall, a pair of angled sides with pockets for the lenses, and a pair of rounded ends. A pocket is disposed on each of the angled sides. The pocket is formed to receive the lens. Each pocket extends from the top to the bottom wall and from one of the pair of rounded ends to the other of the pair of rounded ends. A plurality of vertical exterior ribs which extend beyond the exposed surface of the lens to provide a gap between the lens surface and the tire.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. Provisional Application61/326,402 filed on Apr. 21, 2010. This Application claims the benefitof U.S. Provisional Application 61/365,091 filed on Jul. 16, 2010. ThisApplication claims the benefit of U.S. Provisional Application61/386,120 filed on Sep. 24, 2010, the disclosures of which areincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a road marker having a solid bodyadapted to withstand tensile forces of a vehicle tire and lensprotection in the form of vertical exterior ribs which extend beyond theexposed surface of the lens to provide a gap between the lens surfaceand the tire.

BACKGROUND OF THE INVENTION

Road markers having reflective lenses are used to delineate lanes ofroads. In the past, road markers typically have a shell with aretroreflective lens. The interior side of the retroreflective lens ismetallized and the interior of the shell is filled with a “potting”material to provide strength and rigidity to the shell. Recently, roadmarkers having “solid” bodies have been produced to eliminate the needfor “potting”. These markers have not been successful in several ways.In some cases the bodies have fatigued. Some markers are formed withinterior channels which are covered on the bottom wall with a plasticpanel. However, the plastic panel has very low surface energy resultingin poor retention to the road surface. Additionally, the lens surfacehas been subjected to substantial degradation from abrasion of sandparticles carried by the tires of vehicles. Accordingly, it remainsdesirable to have a road marker with a solid body operable to resistfatigue, has a greater road surface retention relative to current roadmarkers, and withstand degradation from the passing of tires.

SUMMARY OF THE INVENTION AND ADVANTAGES

A road marker having a solid body, at least one lens, and lensprotection in the form of vertical exterior ribs which extend beyond theexposed surface of the lens to provide a gap between the lens surfaceand the tire is provided. The road marker is configured to withstand theforce of a tire of a vehicle travelling over the road marker.

The road marker includes at least one lens having a reflective surface.The road marker further includes a body having a trapezoidal crosssection. The body further includes a flat top, a bottom wall, a pair ofangled sides with pockets for the lenses, and a pair of rounded ends.

A pocket is disposed on each of the angled sides. The pocket is formedto receive the lens. Each pocket extends from the top to the bottom walland from one of the pair of rounded ends to the other of the pair ofrounded ends. The road marker further includes a plurality of verticalexterior ribs which extend beyond the exposed surface of the lens toprovide a gap between the lens surface and the tire.

In a first preferred embodiment, the road marker further includes aplurality of recesses extending downwardly an equal distance from thetop and angled sides to the bottom wall. The recesses are generallyrectangular. The bottom wall of each angled side is curved outwardly toprovide additional area for the lens and to provide a smooth surface forthe tires. Each of the pair of rounded ends are contoured from the topto the bottom wall, each of the pair of rounded ends further including aflange extending outwardly from each of the pair of rounded ends.

The bottom wall includes a lip bounding the peripheral edge of thebottom wall so as to define a recess in the center of the bottom wall,and a layer of polyurethane configured to fittingly engage the recess.The road marker further includes a plurality of grooves disposed on eachof the pockets. The plurality of grooves extending axially from the topwall towards the bottom wall, the grooves are generally parallel witheach other.

Each lens includes a plurality of vertically extending energy directorsare also formed in the interior surface of the lens, the energydirectors operable to facilitate ultrasonic welding of the lenses to thebody. The plurality of vertical exterior ribs is disposed on each lens.

In a second preferred embodiment, the body is formed of cast aluminumand includes a center portion formed on the top, the center portion hasan opening. The pocket is a plurality of pockets formed on each of theangled sides. Each of the plurality of pockets is formed by a verticalsurface and a horizontal surface. The horizontal and vertical surfacesmeet to form a plurality of corners and a plurality of steps.

The lens has a horizontal and vertical interior surface. The lens isconfigured to seat within one of the plurality of pockets. A pluralityof ribs extends from the top to the bottom wall. The ribs form aplurality of pockets stacked on top of each other so as to form a stackof pockets. Each of the plurality of ribs extends beyond the cornerformed by adjacent horizontal and vertical surfaces. Each of thevertical surfaces includes a concave depression so as to reduce mass ofthe road marker and help direct tire pressure transversely across thebody of the road marker.

In an illustrative example, the horizontal and vertical surfaces aregenerally orthogonal to each other. Each lens has an outer surface whichextends at an approximately 45 degree angle and the horizontal andvertical interior surface are orthogonal to each other. The lenses aremounted within each pocket. The outer surface of the lens is recessedslightly from ribs and corners which define each pocket.

The bottom wall surface of the marker is generally planar with a seriesof grooves with a tire tread like pattern formed in the surface toreceive glue. The road marker may further include semicircular notchesformed on each of the rounded ends to facilitate the gripping of themarker for insertion in the road surface. The road marker may furtherinclude a retroreflective sheeting disposed along the vertical surfaceof the lens.

In a third preferred embodiment, the bottom wall includes a plurality ofgrooves operable to increase the retention ability of the road marker tothe road surface. The plurality of grooves includes a plurality ofhorizontal grooves extending in a longitudinal direction. A pair ofradially extending grooves extending radially from a respective point onthe center of the longitudinal axis to a respective end portion of thebody.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated,as the same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings wherein:

FIG. 1 is a perspective view of a first preferred embodiment of a roadmarker of the present invention;

FIG. 2 is a perspective view of the road marker of FIG. 1, taken fromthe opposite side;

FIG. 3 is a perspective view of the underside of the road marker of FIG.1;

FIG. 4 is a perspective view of road marker of FIG. 3, showing the roadmarker fitted with a thin layer of polyurethane;

FIG. 5 is a perspective view of the exterior surface of a lens;

FIG. 6 is a perspective view of the interior surface of a lens;

FIG. 7 is an illustrative view of a second preferred embodiment of aroad marker of the present invention;

FIG. 8 is an illustrative view of the road marker of FIG. 7 without thelens inserted into the pockets;

FIG. 9 is an isolated view of a lens for use in the road marker of FIG.8;

FIG. 10 is a perspective view showing the underside of the road markerof FIG. 8;

FIG. 11 is an illustrative view of another embodiment of the road markerof the second preferred embodiment;

FIG. 12 is an illustrative view of a third preferred embodiment of aroad marker of the present invention;

FIG. 13 is an illustrative view of the road marker of FIG. 12 taken fromthe opposite side; and

FIG. 14 is a view of the underside of the road marker of FIG. 12.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the Figures, wherein like numerals indicate correspondingparts throughout the several views, a road marker 10 having a solid body12, at least one lens 14, and lens 14 protection in the form of verticalexterior ribs 16 which extend beyond the exposed surface of the lens 14to provide a gap between the lens 14 surface and the tire is provided.

The body 12 has a generally rectangular footprint with a trapezoidalcross section. The body 12 has a flat top 18, bottom wall 20, a pair ofangled sides 22 with pockets 24 for the lenses 14, and a pair of ends26. Each angled side 22 has at least one pocket 24, each are formed toreceive the lens 14. The pockets 24 extend from the top 18 to the bottomwall 20 and from end 26 to end 26.

With reference now to FIGS. 1-6, a first preferred embodiment of theroad marker 10 is provided. The marker has a body 12 molded of a plasticmaterial such as ABS, a pair of lens 14 for insertion into a respectivepocket 24, and a thin layer 28 of polyurethane formed on the bottom wall20 of the body 12.

With reference now to FIG. 1, the pockets 24 are formed to receive thelens 14. Each pocket 24 extends from the top 18 to the bottom wall 20and from end 26 to end 26. The pockets 24 are formed recessed from theouter surface of the angled sides 22. The pockets 24 are configured tofittingly hold a lens 14.

The bottom wall 20 of each angled side 22 is curved outwardly to provideadditional area for the lens 14 and to provide a smooth surface for thetires. The pockets 24 are also countoured. Likewise, the ends 26 arecontoured from the top 18 to the bottom wall 20 where a flange 30extends from each end 26.

As shown in FIGS. 1 and 2, the body 12 has a plurality of elongatedrecesses 32 extending downwardly an equal distance from the top 18 andangled sides 22 to a bottom wall 20. The elongated recesses 32 aregenerally rectangular and are formed to provide sufficient strength tothe body 12 to help the road marker 10 resist the impact of vehicles. Ithas been found during testing that when the marker is subjected to aload from a vehicle, there is flexural stress. The tensile portion ofthe stress is focused on the marker. The bottom wall 20 extendstransversely to absorb the tensile stress properly.

With reference now to FIG. 3 a view of the bottom wall 20 is provided.The bottom wall 20 has a generally rectangular recessed surface 34 whichextends inwardly into the bottom wall 20. The bottom wall 20 includes alip 36 bounding the peripheral edges of the bottom wall 20. The lip 36extends beyond the surface of the center of the bottom wall 20 so as todefine the recessed surface 34 in the center of the bottom wall 20. Therecessed surface 34 may be displaced 0.020″ from the outer surface ofthe lip 36.

There are additional depressions 38 formed on the underside of the body12 where there are large portions of material of the body 12 such asunder the ends 26. The depressions 38 are formed to eliminate unneededplastic material.

With reference now to FIG. 4, the road marker 10 may further include athin layer 28 of polyurethane. The thin layer 28 of polyurethane isconfigured to be fittingly engaged within the recessed surface 34. Thethin layer 28 of polyurethane has better retention with adhesives thanthe ABS plastic of the body 12, and thus improves the overall roadretention of the road marker 10 relative to road markers 10 with ABSplastic bottom walls 20. In instances where the lip 36 extends beyondthe surface of the center of the bottom wall 020″, the thin layer 28 ofpolyurethane has a thickness of approximately 0.020″ so as to form agenerally flush and even bottom wall 20 surface.

With reference now to FIGS. 5 and 6, each lens 14 is generallyrectangular, and has a generally planar outer surface and cube corners40 formed on the interior surface. With reference first to FIG. 6, aview of the back angled side 22 of the lens 14 is provided. As shown, aplurality of vertically extending energy directors 42 are also formed inthe interior surface of the lens 14. The energy directors 42 are used tofacilitate ultrasonic welding of the lenses 14 to the body 12.

With reference now to FIG. 5, a view of the front angled side 22 of thelens 14 is provided. A plurality of vertical ribs 16 is formed on theexterior surface of the lens 14. Preferably, the ribs 16 are oppositeeach respective energy director 42. The ribs 16 extend outwardly beyondthe exposed surface of the lens 14 to keep the surface of a tire passingover the lens 14 from abrading the exposed surface. The ribs 16 aregenerally triangular in cross section and extend over the energydirectors 42 to minimize the loss of cube corners 40 which occurs fromthe formation of the energy directors 42.

With reference now to FIGS. 7-11, a second preferred embodiment of aroad marker 110 of the present invention is provided, wherein like partsare indicated by numerals offset by 100. The body 112 may be formed ofdurable and rigid material. For instance, the body 112 may be formed ofaluminum or a moldable material such as molded, suitable plastic such asABS, reinforced glass, fiberglass, or other composite material aluminum.The road marker 110 includes a plurality of replaceable lens 114configured in segments. The lens 114 segments are protected by verticalribs 116 which extend between the lens 14.

With reference first to FIG. 8, the body 112 of the marker may be formedin one piece of cast aluminum. Aluminum is more resistant to wear thanplastics. The body 12 has a generally rectangular footprint and atrapezoidal cross section. The body 112 has a bottom wall 120, twoangled sides 122 extending between a pair of ends 126, and a centerportion with an opening 44. Accordingly, the opening 44 is formed in thecenter to reduce the amount of material used to form the marker.

With reference now to FIG. 11, the body 112 is formed from a moldableplastic. The pockets 124 are formed along the angled sides 122 of theroad marker 110. Each pocket 124 has a generally vertical surface 48 anda horizontal surface 50 to support a lens 114. A plurality of ribs 116extend from the top 118 to the bottom wall 120. The horizontal andvertical surfaces 50,48 form a pocket 124 for a respective lens 14.Though FIG. 11, shows the angled sides 122 including a row of threepockets 124 separated by ribs 116 extending from the top 118 to thebottom wall 120, it should be appreciated by those skilled in the artthat the angled sides 122 may include multiple pockets 124 arranged invarious configurations such as stacked on top 18 of each other so as toform columns of pockets 124 in a side-by-side relationship, as shown inFIG. 8.

With reference again to FIG. 8, each angled side 122 wall of the body112 includes a plurality of pockets 124 stacked on top 118 of each otherso as to form a stack of pockets 52. The ribs 16 extend beyond thecorner 54 formed by adjacent horizontal surfaces 50 and verticalsurfaces 48. Each pocket 124 within the stack of pockets 52 are formedby horizontal and vertical surfaces 50, 48 which meet at a corner 54 soas to form a step 56. The ribs 116 compartmentalize the stack of pockets52 so as to form three stacks of pockets 24 arranged in a side-by-siderelationship.

The ribs 116 are further operable to support tranverse walls 46 formingthe opening 44 of the body 112. The figure shows the horizontal andvertical surfaces 50, 48 being generally orthogonal to each other.However, it should be appreciated that angle of the surface is selectedin accordance with the angle walls of lens 114 as discussed below. Eachof the vertical surfaces 48 includes a concave depression 58 so as toreduce mass of the road marker 10. Further, the concave depressions 58help direct tire pressure transversely across the body 112 of the roadmarker 110.

As shown in FIG. 9, each lens 114 element has an outer surface 114 awhich extends at approximately a forty-five degree angle with respect tohorizontal and vertical interior surfaces 114 b, 114 c which aregenerally orthogonal to each other. The lenses 114 are mounted withineach pocket 124. The outer surface of the lens 114 is recessed slightlyfrom ribs 116 and corners 54 which define each pocket 124.

As shown in FIG. 10, the surface of the bottom wall 120 of the marker isgenerally planar with a series of second grooves 60 with a tire treadlike pattern formed in the surface to receive glue. Semicircular notches62 extend into each end 126 surface to facilitate the gripping of themarker for insertion in the road surface.

Each lens 114 may further include a retroreflective sheeting 64 alongthe vertical surface 48 of the lens 114. The lens 114 is glued into thepocket 124. The use of independent lens 114 segments permits replacementof the segments of lens 114 to prevent crack propagation along theentire width of the road marker 110 relative to road markers with singlelenses spanning the width of the road marker. The ribs 116 preventcracks will not propagate the entire width of the body 12 of the roadmarker 110. Additionally, the segment of lenses 14 may be replaced ifdamaged.

The lens 114 may be formed of plastic or glass. The vertical wall or theouter wall of the lens 114 can be set at a desired angle to maximize thereflectivity of the reflective sheeting according to the Snell principleas discussed in provisional patent application No. 61/288,687.

With reference now to FIGS. 12-14, a third embodiment of the road marker210 is provided, wherein like parts are indicated by numerals offset by200. The body 212 is molded in a single piece of plastic such as ABS.The body 212 has a generally rectangular footprint and a trapezoidalcross section. The body 212 has a bottom wall 220, two angled sides 222extending between a pair of ends 226. The body 212 includes a raisedcenter portion with an opening 244 extending downwardly from a top 218.The opening 244 is formed in the center to reduce the amount of materialused to form the marker.

The body 212 has a plurality of vertical elongated recesses 232surrounding the opening 244. The vertical elongated recesses 232 extenddownwardly to the bottom wall 220 as in the first embodiment. Theelongated recesses 232 are generally rectangular and extend through thelens 214 pocket 224 as well as the center portion of the road marker210. These elongated recesses 232 are also intended for not to exceedthe maximum wall thickness of the plastic injection molding, varyingfrom plastic to plastic approximately to 0.145″of wall thickness.

Each angled side 222 has at least one pocket 224, each are formed toreceive the lens 214. The pockets 224 extend from the top 218 to thebottom wall 220 and from end 226 to end 226 of the body 212. The pockets224 may include a plurality of has a plurality of elongated recesses 232extending downwardly from the outer surface of the pockets 224 towardsthe bottom wall 220 of the body 212. The elongated recesses 232 aregenerally rectangular and are formed to provide sufficient strength tothe body 212 to help the road marker 210 resist the impact of vehicles.

The bottom wall 220 of each angled side 222 is curved outwardly toprovide additional area for the lens 214 and to provide a smooth surfacefor the tires. Likewise, the ends 226 are contoured from the top 218 tothe bottom wall 220 where a flange 230 extends from each end 226.

With reference again to FIGS. 5 and 6, the road marker 210 of the thirdpreferred embodiment includes a pair of lenses 214. Each lens 214 isgenerally rectangular in shape, having a generally planar outer surfaceand cube corners 240 formed on the interior surface, With referencefirst to FIG. 5, a view of the back side 222 of the lens 214 isprovided, As shown, a plurality of vertically extending energy directors242 are also formed in the interior surface of the lens 214. The energydirectors 242 are used to facilitate ultrasonic welding of the lenses214 to the body 212.

With reference now to FIG. 6, a view of the front side of the lens 214is provided. A plurality of vertical ribs 216 is formed on the exteriorsurface of the lens 214. Preferably, the ribs 216 are opposite eachrespective energy director 242. The ribs 216 extend outwardly beyond theexposed surface of the lens 214 to keep the surface of a tire passingover the lens 214 from abrading the exposed surface. The ribs 216 aregenerally triangular in cross section and extend over the energydirectors 242 to minimize the loss of cube corners 240 which occurs fromthe formation of the energy directors 242.

As shown in FIG. 14, the bottom wall 220 surface of the marker has aspecially formulated arrangement of third grooves 66 to increase theretention ability of the road marker 210 to the road surface. Acrossmost of the surface of the bottom wall 220 of the base are a pluralityof horizontal third grooves 68 extending in a longitudinal direction.However, each end 226 is provided with a fan of radially extending thirdgrooves 70. The radially extending third grooves 70 extend radially froma point on the center of the longitudinal axis to the end 226. Thehorizontal third grooves 68 resist displacement of the marker by pushfrom a tire and the fans of radial grooves 66, 68, 70 resistdisplacement from twist. Thus disclosed are embodiments of novel solidbody road marker.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

1. A road marker configured to withstand the force of a tire of avehicle travelling over the road marker, the road marker comprising: atleast one lens; a body having a trapezoidal cross section, the bodyfurther including a flat top, a bottom wall, a pair of angled sides withpockets for the lenses, and a pair ends, a pocket disposed on each ofthe angled sides, the pocket formed to receive the lens, each pocketextending from the top to the bottom wall and from one of the pair ofends to the other of the pair of ends; and a plurality of verticalexterior ribs which extend beyond the exposed surface of the lens toprovide a gap between the lens surface and the tire.
 2. The road markeras set forth in claim 1, further including a plurality of recessesextending downwardly an equal distance from the top and angled sides tothe bottom wall, the recesses are generally rectangular.
 3. The roadmarker as set forth in claim 1, wherein the bottom wall of each angledside is curved outwardly to provide additional area for the lens and toprovide a smooth surface for the tires.
 4. The road marker as set forthin claim 1, wherein each of the pair of rounded ends are contoured fromthe top to the bottom wall, each of the pair of rounded ends furtherincluding a flange extending outwardly from each of the pair of roundedends.
 5. The road marker as set forth in claim 1, wherein the bottomwall includes a lip bounding the peripheral edge of the bottom wall soas to define a recessed surface in the center of the bottom wall, and alayer of polyurethane configured to fittingly engage the recessedsurface.
 6. The road marker as set forth in claim 1, further including aplurality of grooves disposed on each of the pockets, the plurality ofgrooves extending axially from the top wall towards the bottom wall, thegrooves are generally parallel with each other.
 7. The road marker asset forth in claim 1, wherein each lens includes a plurality ofvertically extending energy directors are also formed in the interiorsurface of the lens, the energy directors operable to facilitateultrasonic welding of the lenses to the body.
 8. The road marker as setforth in claim 1, wherein the plurality of vertical exterior ribs aredisposed on each lens.
 9. The road marker as set forth in claim 1,wherein each of the pair of ends are rounded.
 10. The road marker as setforth in claim 1, wherein the body is formed of cast aluminum andincludes a center portion formed on the top, the center portion havingan opening.
 11. The road marker as set forth in claim 10, wherein thepocket is a plurality of pockets formed on each of the angled sides,each of the plurality of pockets formed by a vertical surface and ahorizontal surface, a plurality of corners formed by one of thehorizontal surface adjacent a vertical surface, the horizontal andvertical surfaces also forming a step; the lens having a horizontal andvertical interior surface, the lens configured to seat within one of theplurality of pockets; and a plurality of ribs extend from the top to thebottom wall, the ribs forming plurality of pockets stacked on top ofeach other so as to form a stack of pockets, each of the plurality ofribs extending beyond the corner formed by adjacent horizontal andvertical surfaces.
 12. The road marker as set forth in claim 11, whereineach of the vertical surfaces includes a concave depression so as toreduce mass of the road marker and help direct tire pressuretransversely across the body of the road marker.
 13. The road marker asset forth in claim 11, wherein the horizontal and vertical surfacesbeing generally orthogonal to each other.
 14. The road marker as setforth in claim 11, wherein each lens has an outer surface which extendsat an approximately degree angle and the horizontal and verticalinterior surface are orthogonal to each other, the lenses are mountedwithin each pocket, the outer surface of the lens is recessed slightlyfrom ribs and corners which define each pocket.
 15. The road marker asset forth in claim 11, wherein the bottom wall surface of the marker isgenerally planar with a series of grooves with a tire tread like patternformed in the surface to receive glue.
 16. The road marker as set forthin claim 11, further including semicircular notches formed on each ofthe rounded ends to facilitate the gripping of the marker for insertionin the road surface.
 17. The road marker as set forth in claim 11,further including a retroreflective sheeting disposed along the verticalsurface of the lens.
 18. The road marker as set forth in claim 1,wherein the bottom wall includes a plurality of grooves operable toincrease the retention ability of the road marker to the road surface,the plurality of grooves including a plurality of horizontal groovesextending in a longitudinal direction, a pair of radially extendinggrooves extending radially from a respective point on the center of thelongitudinal axis to a respective end portion of the body.